Method of making and using glass fiber forming feeders

ABSTRACT

A method of making an orificed discharge wall for supplying a plurality of streams of molten inorganic material to be attenuated into filaments comprising inserting elements in apertures in a member; sealing said elements and member within a coating adapted to isostatically transmit pressure to said assembly; applying isostatic pressure to the hermetically sealed elements and member to mechanically seal the elements to the member; and heating the mechanically sealed elements and member to fuse the elements to the member to prevent the unwanted passage of molten glass between said elements and said member, said elements having an orifice to permit the passage of molten glass therethrough to establish said streams.

TECHNICAL FIELD

The invention disclosed herein relates to the production of glass fibersand glass fiber forming feeders.

BACKGROUND ART

With the production of glass fiber forming feeders having anever-increasing number of orifices or tips to supply the streams ofmolten material to be attenuated into filaments, the need for effectiveand efficient systems for attaching the orificed tips or elements in theapertures in the discharge wall has also increased. Previously, theindividual projections or tips were welded to the discharge wall byconventional welding techniques, such as cold resistance welding,electron beam welding, and laser welding and the like. In essence, eachof these systems welded a single tip at a time. With fiber formingfeeders having as many as 4,000 or more tips, the welding process can bequite time consuming. Further, there are other problems associated withthe systems which are well known in the art.

DISCLOSURE OF THE INVENTION

This invention pertains to a method of making an orificed discharge wallfor supplying a plurality of streams of molten inorganic material to beattenuated into filaments comprising: inserting elements in apertures ina member; hermetically sealing said elements and member within a coatingadapted to isostatically transmit pressure to said member and elements;applying isostatic pressure to the hermetically sealed elements andmember to mechanically seal the elements to the member; and heating themechanically sealed elements and member to fuse the elements to themember to prevent the unwanted passage of molten glass between saidelements and said member, said elements having an orifice to permit thepassage of molten glass therethrough to establish said streams.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a semi-schematic front elevational view of a glass textiletype fiber forming system.

FIG. 2 is a semi-schematic front elevational view of a glass wool orrotary fiber forming system.

FIG. 3 is an enlarged cross-sectional view of the discharge wall of thefeeder shown in FIG. 1.

BEST MODE OF CARRYING OUT THE INVENTION

As shown in FIG. 1, feeder 10, which is comprised of containment orsidewalls 12 and an orificed bottom or discharge wall 14, is adapted toprovide a plurality of streams of molten inorganic material, such asglass, through a plurality of orificed elements 85. Feeder 10, includingdischarge wall 14, is adapted to be electrically energized, to heat theglass therein. The streams of molten glass can be attenuated intofilaments 16 through the action of winder 26 or any other suitablemeans.

As is known in the art, size applicator means 18 is adapted to provide acoating or sizing material to the surface of the glass filaments whichadvance to gathering shoe or means 20 to be collected as an advancingstrand or bundle 22. Strand 22 is then wound into package 24 upon acollet of winder 26 as is known in the art. Thus, FIG. 1 schematicallyrepresents a "textile" fiber forming system.

As shown in FIG. 2, rotary system 40 is comprised of a flow means orchannel 42 having a body of molten inorganic material 44, such as glass,therein. A stream of molten glass 46 is supplied to rotary feeder orrotor 50 from channel 42, as is known in the art.

Rotor 50, which is adapted to be rotated at high speeds, is comprised ofa quill 52 and a circumferential fiberizing or discharge wall 54 havinga plurality of orificed elements 85 adapted to supply a plurality ofstreams of molten inorganic material to be fiberized. Such elements maybe flush with the exterior surface of the wall or project outwardlytherefrom.

In conjunction with rotor 50, a shroud 56 and circumferential blower orfluidic attentuation means 57 are adapted to fluidically assist in theattenuation of the streams of molten material into fibers or filaments60. A binder material or coating may be applied to fiber 60 by means ofbinder applicators 58 as is known in the art.

As is shown in the drawings, member 69 of the fiberization or dischargewalls 14 or 54 of the feeders 10 and 50, respectively, may be based upona laminate comprised of a refractory metal core 70 having an oxygenimpervious, precious metal sheath intimately bonded thereto by hotisostatic pressing (i.e., HIP) as is disclosed in my patent applicationSer. No. 200,677, filed on Oct. 27, 1980, which is hereby incorporatedby reference. Or, member 69 may be comprised entirely of any suitablematerial, such as a platinum and rhodium alloy which, for example, iswell known in the art.

Regarding the laminated member, such refractory metals are selected fromthe group of materials consisting of molybdenum (Mo), columbium (Cb),tungsten (W), rhenium (Re), tantalum (Ta), hafnium (Hf), titanium (Ti),chromium (Cr), zirconium (Zr), vanadium (V), and base alloys of suchrefractory metals. For example, an alloy of molybdenum, titanium andzirconium, known as TZM, has been shown to provide a superior laminatedwall for a fiber forming feeder when clad with a precious metal alloy ofplatinum and rhodium.

Particularly, the precious metals for first layer 78, second layer 79and/or elements 85 are selected from a group consisting of platinum(Pt), paladium (Pd), irridium (Ir), osmium (Os), rhodium (Rh), ruthenium(Ru), and alloys based on such metals. Included in the platinum alloysare H alloy and J alloy which are alloys of platinum and rhodium of90%/10% and 75%/25% composition, respectively. In essence, the laminateis comprised of a plurality of layers of material wherein one of saidlayers is a refractory metal, and another of said layers is an oxygenimpervious, precious metal, said plurality of layers being intimatelybonded together by the application of isostatic pressure and heat toform a unitary laminate.

FIG. 3 depicts a portion of a discharge wall at a point duringfabrication according to the principles of this invention. As such,elements or tips 85 are positioned in or inserted in a plurality ofapertures 71 located in member 69. Then a coating 94 is applied to theassembled member 69 and elements 85 to hermetically seal the elementsand member therewithin. The coating or material 94 must be capable ofisostatically transmitting fluidic pressure to member 69 and elements85, and the coating material must prevent the migration of the workingfluid in the pressing unit, either CIP or HIP, between the matingsurfaces of member 69 and elements 85. As will be explained laterherein, when cold isostatic pressing (CIP) is employed, such coatingmaterials are preferably elastomers.

Then, isostatic pressure is applied to the sealed, that is coated,assembly sufficient to mechanically seal or join the elements 85 tomember 69. With the subsequent application of heat, the mechanicallysealed elements and member are fused together to prevent the unwantedpassage of molten glass between the elements 85 and member 69 ofdischarge walls 14 and 54.

A glass fiber forming feeder discharge wall 14 was fabricated from aplatinum-rhodium alloy plate or member 69 and a plurality ofplatinum-rhodium alloy elements or tips 85. As such, member 69 contained800 apertures which each received an element 85. Each of the elements ortips 85 were comprised of a sleeve 87 and a flange 89. An orifice 86within sleeve 87 extended from first end 88 at flange 89 to a second end91 along sleeve 87. As shown in FIG. 3, second end 91 was closed.However, it is to be understood that tips 85 may be supplied with anopen second end 91 such that orifice 86 extends completely throughelement 85.

The elements 85 were inserted into aperture 71 of member 69 such thatflange 89 was in abutting engagement with one side of member 69 and suchthat a portion of sleeve 87, including second end 91, extended beyondthe opposite side of member 69.

The loose assembly of elements 85 and member 69 was then dipped in aliquid bath of polyvinylchloride (PVC) to coat the exposed surfaces ofelements 85 and member 69 and to fill orifices 86 of element 85. Afterthe application of the liquid coating, a slight vacuum was applied toassist in the complete filling of the orifices 86 with the elastomericmaterial. The PVC was then cured or solidified to seal elements 85 andmember 69 against the migration of the working fluid in the pressingunit therebetween.

The coated assembly was then placed in the oil bath of a cold isostaticpressing (CIP) unit, and a pressure of about 150,000 psi was brieflyexerted on the coated assembly to mechanically seal or join the elementsto the member. Since cold isostatic pressure or pressing was employed,the operation was carried forth at approximately room temperature.

Subsequent to the application of isostatic pressure in the CIP unit, theelastomeric coating 94 was slit and removed from member 69 and elements85. Then the sub-assembly, comprised of the mechanically sealed elementsand member 69, was placed in a heating means or furnace and heated to atemperature of about 1200° C. for about one hour to fuse the elements tothe member to form the discharge wall such that during subsequentoperation as a fiber forming feeder the molten glass is prevented fromflowing between the elements and the member.

The second ends 91 of elements 85 may then be machined to open orifice86, if necessary, and sidewalls, and the like, normally associated withfiber forming feeders are joined to the discharge wall to form a fiberforming feeder.

If the orifices 86 are not completely filled with the pressuretransmitting media 94, the sleeves 87 may collapse upon the applicationof the pressure. Also, if the refractory metal laminate is employed, thefusion step should be performed in a vacuum, such as in a vacuumannealing furnace, or in an inert atmosphere to prevent the possibilityof oxidizing the core of the laminate prior to the fusion of theprecious metal layers and the elements.

Although in the foregoing example, the member 69 was completely encasedwithin the pressure transmitting coating 94, it is only necessary thatthe elements 85 and that portion of member 69 associated therewith behermetically sealed by the coating. That is, other portions of member 69may be left uncoated.

Alternatively, a thermoplastic material, such as a suitable glass, maybe employed as the coating material 94. However, since most glasses arebrittle at room temperature, the application of heat and isostaticpressure should take place simultaneously at a temperature at which theglass becomes pliable and capable of transmitting the pressure appliedthereto isostatically to the member and elements. As such, theapplication of isostatic pressure and heat should be performed in a hotisostatic pressing (HIP) unit. Also, it may be desirable to suitablypreheat the assembly sealed in the glass coating to a suitable softeningtemperature prior to any substantial application of pressure to preventthe fracture of the glass coating by the pressure.

In either case, the coating material should not be too fluid or pliable.That is, the coating 94 should be sufficiently viscous to prevent theflow of the coating between the elements 85 and member 69 which mayprevent the effective sealing of elements 85 to member 69.

According to the foregoing procedures, if a tip 85 as shown in FIG. 3 isemployed, the flange 89 will be fused to one surface of member 69 andsleeve 87 will be fused to the portion of member 69 defining theapertures 71 associated therewith. Further, if the refractorymetal/precious metal laminate is employed as member 69, the sleeve 87 ofelement 85 will fuse to core 70 and layers 78 and 79 to seal therefractory metal within a protective layer of oxygen impervious,precious metal to prevent the oxidation of the refractory metal atelevated temperatures.

Also, it is to be understood that element 85 may be of any suitableshape, and, in particular, flange 89 may be dispensed with and/or thelength of sleeve 87 may also be substantially equal to the thickness ofmember 69 to provide a tipless orifice plate having orifices lined witha suitable material fused to the member 69.

To provide an effective mechanical seal between the elements and memberin the isostatic pressing step, it is preferred that the isostaticpressure applied be greater than or equal to the yield point of thematerial of the elements 85 at the temperature employed for the pressingstep.

From the foregoing, it can be seen that the present invention isapplicable to the joining of the precious metal elements to thelaminated walls or members as disclosed in, for example, U.S. patentapplication Ser. No. 200,676 filed Oct. 27, 1980, now U.S. Pat. No.4,342,577, issued Aug. 3, 1982 in the names of Mohinder S. Bhatti andAlfred Marzocchi; and/or U.S. patent application Ser. No. 255,987 filedApr. 20, 1981 in my name, now U.S. Pat. No. 4,343,636, issued Aug. 10,1982, which are hereby incorporated by reference.

It is apparent that within the scope of the present invention,modifications and different arrangements can be made other than asherein disclosed. The present disclosure is merely illustrative, withthe invention comprehending all variations thereof.

INDUSTRIAL APPLICABILITY

The invention disclosed herein is readily applicable to the formation ofcontinuous and/or staple glass filaments.

What is claimed is:
 1. In a method of making glass filaments wherein aplurality of streams of molten glass issuing from an orificed dischargewall of a feeder are attenuated into said filaments, the improvementcomprising said discharge wall being fabricated by:inserting elements inapertures in a member; hermetically sealing said elements and memberwithin a coating adapted to isostatically transmit pressure to saidelements and member; applying isostatic pressure to the hermeticallysealed elements and member to mechanially seal the elements to themember; and heating the mechanically sealed elements and member to fusethe elements to the member to prevent the unwanted passage of moltenglass between said elements and said member, said elements having anorifice to permit the passage of molten glass therethrough to establishsaid streams.
 2. A method of making an orificed discharge wall forsupplying a plurality of streams of molten inorganic material to beattenuated into filaments comprising:inserting elements in apertures ina member; sealing said elements and member within a coating adapted toisostatically transmit pressure to said elements and member; applyingisostatic pressure to the sealed elements and member to mechanicallyseal the elements to the member; and heating the mechanically sealedelements and member to fuse the elements to the member to prevent theunwanted passage of molten glass between said elements and said member,said elements having an orifice to permit the passage of molten glasstherethrough to establish said streams.
 3. The method of claim 2 whereinthe pressure is applied approximately at room temperature and thepressure is greater than or equal to the yield point of the material ofthe elements at such temperature.
 4. The method of claim 3 wherein thecoating is an elastomeric material.
 5. The method of claim 4 wherein thecoating is polyvinylchloride.
 6. The method of claim 3 wherein themechanically sealed elements and member are heated subsequent to theapplication of said isostatic pressure.
 7. The method of claim 2 whereinsaid hermetically sealed elements and member are cold isostaticallypressed.
 8. The method of claim 2 wherein said hermetically sealedelements and member are hot isostatically pressed.
 9. The method ofclaim 2 wherein said member is a laminate comprised of a plurality oflayers of material wherein one of said layers is a refractory metal andanother of said layers is an oxygen impervious, precious metal, saidplurality of layers being intimately bonded together by the applicationof isostatic pressure and heat to form a unitary laminate.
 10. Themethod of claim 9 wherein the refractory metal layer is a materialselected from the group consisting of Ti, V, Cb, Ta, Cr, Mo, W, Re andbase alloys thereof and wherein said precious metal layer is a materialof the group consisting of Pt, Pd, Ir, Os, Rh, Ra and base alloysthereof.
 11. The method of claim 10 wherein said elements are selectedfrom the group consisting of Pt, Pd, Ir, Os, Rh, Ru and base alloysthereof.
 12. The method of claim 11 wherein said elements have a flangesealed to said member and a sleeve extending beyond the member.
 13. Themethod of claims 4 or 6 further comprising removing said coating priorto said heating.
 14. The method of claim 8 wherein said coating isglass.
 15. The method of claim 2 wherein said orifices are formed insaid elements subsequent to said heating.
 16. The method of claim 2wherein said inorganic material is glass.
 17. An article for fabricationinto a glass fiber forming feeder comprising:a member having a pluralityof elements positioned in apertures therein; and a coating in contactwith said member and elements sealing said elements and at least aportion of said member to permit the application of isostatic pressurethereto to mechanically seal the elements to the member.
 18. The articleof claim 17 wherein said coating is selected from the group of materialscomprising elastomers and thermoplastics.
 19. The method of claim 17wherein said coating is selected from said group consisting ofpolyvinylchloride and glass.